Consumable tip burners, submerged combustion melters including same, and methods

Abstract

Combustion burners, burner panels, submerged combustion melters including the panels, and methods of using the same are disclosed. In certain embodiments, the burner includes an annular liquid cooled jacket defining a central longitudinal through passage. An inner conduit is positioned substantially concentrically within an outer conduit, the latter positioned in the through passage, each conduit comprising proximal and distal ends, the conduits configured so that the outer and inner conduits are movable axially. The inner conduit forms a primary passage and the outer conduit forms a secondary passage between the outer conduit and the inner conduit. In one embodiment the outer conduit has an exterior surface configured along at least a portion thereof with threads mating with adjacent threads on an inner surface of the annular liquid cooled jacket. Other embodiments including lock and release dogs or bolt arrangements. The burners promote burner life and melter campaign length.

What is claimed is: 
     
       1. A combustion burner for submerged combustion comprising:
 (a) an annular liquid cooled jacket defining a central longitudinal through passage; 
 (b) at least one inner conduit and a substantially concentric outer conduit positioned in the through passage, each conduit comprising proximal and distal ends, all conduit distal ends extending beyond a distal end of the annular liquid cooled jacket, the conduits configured so that the outer and inner conduits are movable axially, the at least one inner conduit forming a primary passage and the outer conduit forming a secondary passage between the outer conduit and the at least one inner conduit, the at least one inner conduit and the outer conduit having positions selected from the group consisting of:
 (i) the distal end of the outer conduit extends beyond the distal end of the at least one inner conduit, and 
 (ii) the distal end of the at least one inner conduit extends beyond the distal end of the outer conduit; and 
 
 (c) the outer conduit having an exterior surface configured along a lower portion thereof with at least two sets of axially spaced dog teeth, one set mating with adjacent dog teeth on one or more dog connectors secured in the annular liquid cooled jacket, the one or more dogs connectors configured to be operable hydraulically between a locked position and a release position, allowing the outer conduit to be repositioned axially relative to the annular liquid cooled jacket. 
 
     
     
       2. The burner of  claim 1  wherein each conduit consists of a material having a wear rate that is less than noble metals when used in a submerged combustion melter. 
     
     
       3. The burner of  claim 2  wherein the materials is selected from the group consisting of ceramic materials, non-noble metals, and combinations thereof. 
     
     
       4. The burner of  claim 3  wherein the non-noble metals is carbon steel. 
     
     
       5. The burner of  claim 1  wherein the outer conduit is noble metal and the one or more inner conduits is a non-noble metal material. 
     
     
       6. The burner of  claim 1 , the annular liquid cooled jacket secured in a burner panel. 
     
     
       7. A submerged combustion melter including one or more burner panels of  claim 6 . 
     
     
       8. The burner of  claim 1  wherein the conduits are configured so that the outer and inner conduits are movable axially in unison. 
     
     
       9. The burner of  claim 1  wherein the conduits are configured so that the outer and inner conduits are movable axially separately. 
     
     
       10. A method of melting non-metallic inorganic feedstock using the submerged combustion melter of  claim 7 , the method comprising:
 (a) positioning the distal ends of the inner and outer conduits of the combustion burner at an initial position beyond a wall of the submerged combustion melter; 
 (b) feeding the feedstock into the submerged combustion melter and melting the feedstock using the combustion burner during a first time period during which the inner and outer conduits wear away to a second position closer to the wall of the submerged combustion melter; 
 (c) advancing the inner and outer conduits so that their distal ends are substantially at their initial position; and
 (d) melting the feedstock during a second time period using the combustion burner. 
 
 
     
     
       11. A method of melting non-metallic inorganic feedstock using the submerged combustion melter of  claim 1 , the method comprising:
 (a) positioning the distal ends of the inner and outer conduits of the combustion burner at an initial position beyond a wall of the submerged combustion melter; 
 (b) feeding the feedstock into the submerged combustion melter and melting the feedstock using the combustion burner during a first time period during which the inner and outer conduits wear away to a second position closer to the wall of the submerged combustion melter; 
 (c) advancing the inner and outer conduits so that their distal ends are substantially at their initial position; and 
 (d) melting the feedstock during a second time period using the combustion burner.